The challenge
What needed to change.
Single packs were manually grouped into pairs before entering the next conveyor. Replacing the complete line would have added unnecessary cost and disruption.
Machine builds · Food, beverage & packaging
Twin-pack infeed retrofit
A packaging-line retrofit that automates pack pairing while retaining the productive parts of the existing equipment.
ClientPladisSectorFood, beverage & packagingPrimary disciplineMachine builds
Adbro’s approach
How the solution was engineered.
Adbro modified the conveyor arrangement and added adaptable handling, vision, encoder feedback, PLC control and a clear operator interface.
The outcome
What the project delivered.
The retrofit reduces manual intervention, improves line efficiency and gives operators the flexibility to run single- and twin-pack formats.
Technical delivery
Inside the engineered solution.
The detail below shows how the main equipment, software and interfaces were brought together—not just what the project achieved.
3operator-selectable running modes2additional conveyors integrated90°diverter transfer into the wrapper
System scope
- Existing conveyor modification
- Two additional conveyors, pack stops and diverter
- Basler camera for pack-position detection
- Encoder-based spacing control
- CompactLogix PLC sequence control
- HMI for single, twin-pack and maintenance modes
Pack accumulation and release
In twin-pack mode, controlled stops accumulate two packs before release. The diverter then transfers the pair through 90 degrees toward the flow-wrapper infeed.
Vision-based position confirmation
A Basler camera monitors pack positions around the pairing process. The stop sequence responds to detected position rather than relying on timing alone.
Encoder-controlled spacing
Conveyor movement is referenced to an encoder so spacing can be maintained through the modified infeed and overfill or starvation of the downstream machine can be avoided.
Defined operating modes
The HMI provides separate sequences for single packs, automatically paired twin packs and manual maintenance control, allowing the retrofit to support both production formats.
Verification & handover
The retrofit was tested through each operating mode, including pack detection, accumulation, spacing, diversion, transfer to the existing equipment, manual controls and recovery from incomplete pack sequences.
Project highlights
Conveyor retrofitPLC & HMIVision guidanceFormat flexibility
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